Hats and patches often get grouped in with general embroidery, but both have their own quirks worth knowing before you order.
Structured vs. unstructured caps
A structured cap (the stiffer, more traditional baseball-cap shape) holds an embroidered logo more crisply than an unstructured or "dad hat" style, which has a softer crown that can slightly distort detailed designs. If your logo has fine detail or small text, ask the shop which cap style they'd recommend before you lock in a blank.
Hooping limitations
Hats have to be mounted on a specialized hat hoop to be embroidered, which limits how large or how low on the cap a design can sit compared to a flat garment. A logo that looks fine on a t-shirt mockup sometimes needs to be resized or repositioned specifically for a cap — ask to see a hat-specific mockup, not just the general logo file, before production.
Patch backing types actually matter
Iron-on patches are the cheapest and easiest for a one-time application but can peel over time, especially through repeated washing. Sew-on patches cost a little more and require actual stitching but hold permanently. Velcro-backed patches cost the most per unit but allow swapping — common for uniforms, vests, or tactical-style gear where patches change over time.
Size drives patch price more than detail
Unlike embroidery on a garment (priced by stitch count), patches are usually priced primarily by physical size and backing type. A simple 2-inch patch and a detailed 2-inch patch often cost close to the same; a simple 2-inch patch and a simple 5-inch patch will not.